Modular wall panels and planar structures

ABSTRACT

A modular glass panel comprising a glass structure having at least one thin glass sheet having a thickness ranging from about 0.5 mm to about 2.0 mm, a backing frame positioned adjacent the glass structure and situated along the perimeter of the glass structure, and a polymer layer intermediate the glass structure and backing frame to adhere the glass structure together with the backing frame. The glass structure can further comprise the at least one thin glass sheet and a second glass sheet having a polymer interlayer therebetween. The backing frame generally has a geometric cross-section with a rounded interior edge adjacent the glass structure to prevent breakage of the structure upon loading or impact of an exterior surface of the structure.

This application claims the benefit of priority under 35 U.S.C. § 365 ofInternational Patent Application Serial No. PCT/US14/47724 filed on Jul.23, 2014, and claims the benefit of priority to U.S. ProvisionalApplication 61/860,539 filed Jul. 31, 2013, the content of which areincorporated herein by reference in their entirety.

BACKGROUND

In conventional elevators, lobbies and other interior architecturalenvironments, glass can be utilized as a wall covering or as the wall.In such environments, soda lime glass or tempered monolithic glass isutilized having thicknesses greater than about 6 mm. Laminated glassstructures are also employed in such settings with multiple glasslayers, each layer also having thicknesses greater than about 6 mm andresulting in an overall laminate glass structure thickness of over 12 mmor more. Furthermore, conventional decoration can employ soda lime glassor tempered monolithic glass mounted over wood, stone or anotherdecorative surface or substrate. Notably, the weight of such wallcoverings and/or glass paneling is rather heavy and on the order ofapproximately five to ten pounds per square foot. Additionally, suchthick glass or glass laminate structures combined with an underlyingwood, stone or other substrate greatly increases the weight of theoverall wall covering or panel.

In an elevator environment, weight is a notable issue where the trendhas been towards lighter elevator cabs. Light-weight elevator cabs,however, generally reduce the load on a respective elevator motor andcan allow for installation of smaller motors. Conventionally, thisweight issue has been addressed by reducing weight in the elevator cabbody and elevator cab framework. This solution, however, has failed toaddress weight savings provided by interior components of the elevatorcab.

SUMMARY

The present disclosure generally relates to interior architecturalelements and the design and manufacture of light-weight, modular,reconfigurable glass panels.

Embodiments of the present disclosure can include a modular glass panelcomprising a glass structure having at least one thin glass sheet havinga thickness ranging from about 0.5 mm to about 2.0 mm or more, a backingframe positioned adjacent the glass structure and situated along theperimeter of the glass structure, and a polymer layer intermediate theglass structure and backing frame to adhere the glass structure togetherwith the backing frame.

Additional embodiments of the present disclosure include a modular panelcomprising a planar structure, a backing frame positioned adjacent theplanar structure and situated along the perimeter of the planarstructure, the backing frame have a geometric cross-section with arounded interior edge adjacent the planar structure to prevent breakageof the planar structure upon loading or impact of an exterior surface ofthe planar structure, and a polymer layer intermediate the planarstructure and backing frame to adhere the planar structure together withthe backing frame.

Additional features and advantages of the claimed subject matter will beset forth in the detailed description which follows, and in part will bereadily apparent to those skilled in the art from that description orrecognized by practicing the claimed subject matter as described herein,including the detailed description which follows, the claims, as well asthe appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description present embodiments of the presentdisclosure, and are intended to provide an overview or framework forunderstanding the nature and character of the claimed subject matter.The accompanying drawings are included to provide a furtherunderstanding of the present disclosure, and are incorporated into andconstitute a part of this specification. The drawings illustrate variousembodiments and together with the description serve to explain theprinciples and operations of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purposes of illustration, there are forms shown in the drawingsthat are presently preferred, it being understood, however, that theembodiments disclosed and discussed herein are not limited to theprecise arrangements and instrumentalities shown.

FIGS. 1A, 1B and 1C are perspective cut-away illustrations of embodimentof the present disclosure.

FIG. 2A is a top plan view of another embodiment of the presentdisclosure.

FIG. 2B is a cross-sectional view of the embodiment of FIG. 2A alongline A-A.

FIG. 2C is a detailed view of FIG. 2B.

FIGS. 3A and 3B are detailed views, similar to FIG. 2C, of furtherembodiments of the present disclosure.

FIG. 4 is an illustration of some embodiments of the present disclosure.

DETAILED DESCRIPTION

With reference to the figures, where like elements have been given likenumerical designations to facilitate an understanding of the presentdisclosure, the various embodiments for modular wall panels and planarstructures are described.

In the following description, like reference characters designate likeor corresponding parts throughout the several views shown in thefigures. It is also understood that, unless otherwise specified, termssuch as “top,” “bottom,” “outward,” “inward,” and the like are words ofconvenience and are not to be construed as limiting terms. In addition,whenever a group is described as comprising at least one of a group ofelements and combinations thereof, it is understood that the group maycomprise, consist essentially of, or consist of any number of thoseelements recited, either individually or in combination with each other.

Similarly, whenever a group is described as consisting of at least oneof a group of elements or combinations thereof, it is understood thatthe group may consist of any number of those elements recited, eitherindividually or in combination with each other. Unless otherwisespecified, a range of values, when recited, includes both the upper andlower limits of the range. As used herein, the indefinite articles “a,”and “an,” and the corresponding definite article “the” mean “at leastone” or “one or more,” unless otherwise specified

The following description of the present disclosure is provided as anenabling teaching thereof and its best, currently-known embodiment.Those skilled in the art will recognize that many changes can be made tothe embodiment described herein while still obtaining the beneficialresults of the present disclosure. It will also be apparent that some ofthe desired benefits of the present disclosure can be obtained byselecting some of the features of the present disclosure withoututilizing other features. Accordingly, those of ordinary skill in theart will recognize that many modifications and adaptations of thepresent disclosure are possible and can even be desirable in certaincircumstances and are part of the present disclosure. Thus, thefollowing description is provided as illustrative of the principles ofthe present disclosure and not in limitation thereof.

Those skilled in the art will appreciate that many modifications to theexemplary embodiments described herein are possible without departingfrom the spirit and scope of the present disclosure. Thus, thedescription is not intended and should not be construed to be limited tothe examples given but should be granted the full breadth of protectionafforded by the appended claims and equivalents thereto. In addition, itis possible to use some of the features of the present disclosurewithout the corresponding use of other features. Accordingly, theforegoing description of exemplary or illustrative embodiments isprovided for the purpose of illustrating the principles of the presentdisclosure and not in limitation thereof and can include modificationthereto and permutations thereof.

In some embodiments of the present disclosure, thin sheets of glass canbe employed as a surface mount on exemplary backing devices or frames orcan be employed as single sheets or as laminate structures withoutbacking devices or frames, or as combinations thereof. Such a structuremay generally be referred to as a panel. Exemplary glass sheets can beformed from chemically-strengthened glass, thermal tempered glass, heatstrengthened glass, annealed glass, soda lime glass, and glass ceramics,just to name a few. Additionally, embodiments of the present disclosurecan employ exemplary polymers or plastics in the place of glass sheets.Exemplary polymeric materials include, but are not limited to, polyvinylbutryal (PVB), ethylene vinyl acetate (EVA), SentryGlass® or otherionomers, polycarbonate, acrylic, and the like. Exemplary glass orpolymeric panels can be suitable for a myriad of interior or exteriorenvironments such as, but not limited to, elevators, walls, standalonewalls (as in partitions), office spaces, lab spaces, entry ways, and thelike.

In additional embodiments of the present disclosure, thin chemicallystrengthened glass, e.g., Gorilla® Glass, can be employed over adecorative element, or with an integrated decorative element, to providea light-weight solution to architectural requirements while providingbenefits of durability and scratch and damage resistant surfaces to theunderlying decoration. Applicant has discovered that by replacingconventionally employed glass products with thin,chemically-strengthened glass the weight of the respective device orpanel is reduced by at least 50% without compromising the safety orimpact performance of the device or panel. Additionally, by employingsuch light-weight and thin glass elements, touch functionality andwireless communication functionality can be employed in embodiments ofthe present disclosure. For example, the Corning ONE Wireless platformcan be utilized with embodiments of the present disclosure as describedbelow. Of course, other distributed wireless or antenna systems can beemployed to gather and/or disseminate information to other deviceswithin a space or exterior to a space such as handheld devices,smartphones and the like for purposes of freely sharing information(information way points) or as points of sale (POS). Additionally,wireless sensor networks (WSN) for environmental monitoring feedback andcontrol, can also be employed with embodiments of the presentdisclosure.

Suitable glass sheets used in embodiments of the present disclosure,whether in a single glass sheet embodiment or in a multi-layer glasssheet embodiment and used as an external and/or internal glass sheet,can be strengthened or chemically-strengthened by a pre- or post-ionexchange process. In this process, typically by immersion of the glasssheet into a molten salt bath for a predetermined period of time, ionsat or near the surface of the glass sheet are exchanged for larger metalions from the salt bath. In one embodiment, the temperature of themolten salt bath is about 430° C. and the predetermined time period isabout eight hours. The incorporation of the larger ions into the glassstrengthens the sheet by creating a compressive stress in a near surfaceregion. A corresponding tensile stress is induced within a centralregion of the glass to balance the compressive stress.

Exemplary ion-exchangeable glasses that are suitable for forming glasssheets or glass laminates can be alkali aluminosilicate glasses oralkali aluminoborosilicate glasses, though other glass compositions arecontemplated. As used herein, “ion exchangeable” means that a glass iscapable of exchanging cations located at or near the surface of theglass with cations of the same valence that are either larger or smallerin size. One exemplary glass composition comprises SiO₂, B₂O₃ and Na₂O,where (SiO₂+B₂O₃)≥66 mol. %, and Na₂O≥9 mol. %. In an embodiment, theglass sheets include at least 6 wt. % aluminum oxide. In a furtherembodiment, a glass sheet includes one or more alkaline earth oxides,such that a content of alkaline earth oxides is at least 5 wt. %.Suitable glass compositions, in some embodiments, further comprise atleast one of K₂O, MgO, and CaO. In a particular embodiment, the glasscan comprise 61-75 mol. % SiO₂; 7-15 mol. % Al₂O₃; 0-12 mol. % B₂O₃;9-21 mol. % Na₂O; 0-4 mol. % K₂O; 0-7 mol. % MgO; and 0-3 mol. % CaO.

A further exemplary glass composition suitable for forming hybrid glasslaminates comprises: 60-70 mol. % SiO₂; 6-14 mol. % Al₂O₃; 0-15 mol. %B₂O₃; 0-15 mol. % Li₂O; 0-20 mol. % Na₂O; 0-10 mol. % K₂O; 0-8 mol. %MgO; 0-10 mol. % CaO; 0-5 mol. % ZrO₂; 0-1 mol. % SnO₂; 0-1 mol. % CeO₂;less than 50 ppm As₂O₃; and less than 50 ppm Sb₂O₃; where 12 mol.%≤(Li₂O+Na₂O+K₂O)≤20 mol. % and 0 mol. %≤(MgO+CaO)≤10 mol. %. A stillfurther exemplary glass composition comprises: 63.5-66.5 mol. % SiO₂;8-12 mol. % Al₂O₃; 0-3 mol. % B₂O₃; 0-5 mol. % Li₂O; 8-18 mol. % Na₂O;0-5 mol. % K₂O; 1-7 mol. % MgO; 0-2.5 mol. % CaO; 0-3 mol. % ZrO₂;0.05-0.25 mol. % SnO₂; 0.05-0.5 mol. % CeO₂; less than 50 ppm As₂O₃; andless than 50 ppm Sb₂O₃; where 14 mol. %≤(Li₂O+Na₂O+K₂O)≤18 mol. % and 2mol. %≤(MgO+CaO)≤7 mol. %.

In a particular embodiment, an alkali aluminosilicate glass comprisesalumina, at least one alkali metal and, in some embodiments, greaterthan 50 mol. % SiO₂, in other embodiments at least 58 mol. % SiO₂, andin still other embodiments at least 60 mol. % SiO₂, wherein the ratio

${\frac{{{Al}_{2}O_{3}} + {B_{2}O_{3}}}{\sum{modifiers}} > 1},$where in the ratio the components are expressed in mol. % and themodifiers are alkali metal oxides. This glass, in particularembodiments, comprises, consists essentially of, or consists of: 58-72mol. % SiO₂; 9-17 mol. % Al₂O₃; 2-12 mol. % B₂O₃; 8-16 mol. % Na₂O; and0-4 mol. % K₂O, wherein the ratio

$\frac{{{Al}_{2}O_{3}} + {B_{2}O_{3}}}{\sum{modifiers}} > 1.$

In another embodiment, an alkali aluminosilicate glass comprises,consists essentially of, or consists of: 61-75 mol. % SiO₂; 7-15 mol. %Al₂O₃; 0-12 mol. % B₂O₃; 9-21 mol. % Na₂O; 0-4 mol. % K₂O; 0-7 mol. %MgO; and 0-3 mol. % CaO. In yet another embodiment, an alkalialuminosilicate glass substrate comprises, consists essentially of, orconsists of: 60-70 mol. % SiO₂; 6-14 mol. % Al₂O₃; 0-15 mol. % B₂O₃;0-15 mol. % Li₂O; 0-20 mol. % Na₂O; 0-10 mol. % K₂O; 0-8 mol. % MgO;0-10 mol. % CaO; 0-5 mol. % ZrO₂; 0-1 mol. % SnO₂; 0-1 mol. % CeO₂; lessthan 50 ppm As₂O₃; and less than 50 ppm Sb₂O₃; wherein 12 mol.%≤Li₂O+Na₂O+K₂O≤20 mol. % and 0 mol. %≤MgO+CaO≤10 mol. %. In stillanother embodiment, an alkali aluminosilicate glass comprises, consistsessentially of, or consists of: 64-68 mol. % SiO₂; 12-16 mol. % Na₂O;8-12 mol. % Al₂O₃; 0-3 mol. % B₂O₃; 2-5 mol. % K₂O; 4-6 mol. % MgO; and0-5 mol. % CaO, wherein: 66 mol. %≤SiO₂+B₂O₃+CaO≤69 mol. %;Na₂O+K₂O+B₂O₃+MgO+CaO+SrO≥10 mol. %; 5 mol. %≤MgO+CaO+SrO≤8 mol. %;(Na₂O+B₂O₃)—Al₂O₃≤2 mol. %; 2 mol. %≤Na₂O—Al₂O₃≤6 mol. %; and 4 mol.%≤(Na₂O+K₂O)—Al₂O₃≤10 mol. %.

Exemplary chemically-strengthened as well as non-chemically-strengthenedglass, in some embodiments, can be batched with 0-2 mol. % of at leastone fining agent selected from a group that includes Na₂SO₄, NaCl, NaF,NaBr, K₂SO₄, KCl, KF, KBr, and SnO₂. In one exemplary embodiment, sodiumions in exemplary chemically-strengthened glass can be replaced bypotassium ions from the molten bath, though other alkali metal ionshaving a larger atomic radii, such as rubidium or cesium, can replacesmaller alkali metal ions in the glass. According to particularembodiments, smaller alkali metal ions in the glass can be replaced byAg⁺ ions. Similarly, other alkali metal salts such as, but not limitedto, sulfates, halides, and the like may be used in the ion exchangeprocess. The replacement of smaller ions by larger ions at a temperaturebelow that at which the glass network can relax produces a distributionof ions across the surface of the glass that results in a stressprofile. The larger volume of the incoming ion produces a compressivestress (CS) on the surface and tension (central tension, or CT) in thecenter of the glass. The compressive stress is related to the centraltension by the following relationship:

${{CS} = {{CT}\left( \frac{t - {2{DOL}}}{DOL} \right)}}\;$where t represents the total thickness of the glass sheet and DOL is thedepth of exchange, also referred to as depth of layer.

According to various embodiments, glass sheets and/or glass laminatestructures comprising ion-exchanged glass can possess an array ofdesired properties, including low weight, high impact resistance, andimproved sound attenuation. In one embodiment, a chemically-strengthenedglass sheet can have a surface compressive stress of at least 250 MPa,e.g., at least 250, 300, 400, 450, 500, 550, 600, 650, 700, 750 or 800MPa, a depth of layer at least about 20 m (e.g., at least about 20, 25,30, 35, 40, 45, or 50 m) and/or a central tension greater than 40 MPa(e.g., greater than 40, 45, or 50 MPa) but less than 100 MPa (e.g., lessthan 100, 95, 90, 85, 80, 75, 70, 65, 60, or 55 MPa). A modulus ofelasticity of a chemically-strengthened glass sheet can range from about60 GPa to 85 GPa (e.g., 60, 65, 70, 75, 80 or 85 GPa). The modulus ofelasticity of the glass sheet(s) and the polymer interlayer can affectboth the mechanical properties (e.g., deflection and strength) and theacoustic performance (e.g., transmission loss) of the resulting glasslaminate.

Exemplary glass sheet forming methods include fusion draw and slot drawprocesses, which are each examples of a down-draw process, as well asfloat processes. These methods can be used to form bothchemically-strengthened and non-chemically-strengthened glass sheets.The fusion draw process generally uses a drawing tank that has a channelfor accepting molten glass raw material. The channel has weirs that areopen at the top along the length of the channel on both sides of thechannel. When the channel fills with molten material, the molten glassoverflows the weirs. Due to gravity, the molten glass flows down theoutside surfaces of the drawing tank. These outside surfaces extend downand inwardly so that they join at an edge below the drawing tank. Thetwo flowing glass surfaces join at this edge to fuse and form a singleflowing sheet. The fusion draw method offers the advantage that, becausethe two glass films flowing over the channel fuse together, neitheroutside surface of the resulting glass sheet comes in contact with anypart of the apparatus. Thus, the surface properties of the fusion drawnglass sheet are not affected by such contact.

The slot draw method is distinct from the fusion draw method. Here themolten raw material glass is provided to a drawing tank. The bottom ofthe drawing tank has an open slot with a nozzle that extends the lengthof the slot. The molten glass flows through the slot/nozzle and is drawndownward as a continuous sheet and into an annealing region. The slotdraw process can provide a thinner sheet than the fusion draw processbecause a single sheet is drawn through the slot, rather than two sheetsbeing fused together.

Down-draw processes produce glass sheets having a uniform thickness thatpossess surfaces that are relatively pristine. Because the strength ofthe glass surface is controlled by the amount and size of surface flaws,a pristine surface that has had minimal contact has a higher initialstrength. When this high strength glass is then chemically strengthened,the resultant strength can be higher than that of a surface that hasbeen a lapped and polished. Down-drawn glass may be drawn to a thicknessof less than about 2 mm. In addition, down drawn glass has a very flat,smooth surface that can be used in its final application without costlygrinding and polishing.

In the float glass method, a sheet of glass that may be characterized bysmooth surfaces and uniform thickness is made by floating molten glasson a bed of molten metal, typically tin. In an exemplary process, moltenglass that is fed onto the surface of the molten tin bed forms afloating ribbon. As the glass ribbon flows along the tin bath, thetemperature is gradually decreased until a solid glass sheet can belifted from the tin onto rollers. Once off the bath, the glass sheet canbe cooled further and annealed to reduce internal stress.

As noted above, exemplary glass sheets can be used to form glasslaminates or glass laminate structures. The term “thin” as used hereinmeans a thickness of up to about 1.5 mm, up to about 1.0 mm, up to about0.7 mm, or in a range of from about 0.5 mm to about 1.0 mm, or fromabout 0.5 mm to about 0.7 mm. The terms “sheet”, “structure”, “glassstructures”, “laminate structures” and “glass laminate structures” maybe used interchangeably in the present disclosure and such use shouldnot limit the scope of the claims appended herewith. As defined herein,a glass laminate can also comprise an externally or internally-facingchemically-strengthened glass sheet, an internally or externally facingnon-chemically-strengthened glass sheet, and a polymer interlayer formedbetween the glass sheets. The polymer interlayer can comprise amonolithic polymer sheet, a multilayer polymer sheet, or a compositepolymer sheet. The polymer interlayer can be, for example, a plasticizedpoly(vinyl butyral) sheet.

FIGS. 1A, 1B and 1C are perspective cut-away illustrations ofembodiments of the present disclosure. With reference to FIG. 1A, anexemplary modular glass panel 100 includes a single, thin light-weightsheet of chemically-strengthened glass 112, e.g., Gorilla® Glass,mounted to a backing frame 114 by an adhesive material 116. Of course,exemplary sheets of glass 112 can be formed from any suitablechemically-strengthened glass, thermal tempered glass, heat strengthenedglass, annealed glass, soda lime glass, or glass ceramic, just to name afew. Additionally, embodiments of the present disclosure can employexemplary polymers or plastics in the place of glass sheets. Exemplarypolymeric materials include, but are not limited to, polyvinyl butryal(PVB), ethylene vinyl acetate (EVA), SentryGlass® or other ionomers,polycarbonate, acrylic, and the like. Exemplary glass or polymericpanels can be suitable for a myriad of interior or exterior environmentssuch as, but not limited to, elevators, walls, standalone walls (as inpartitions), office spaces, lab spaces, entry ways, and the like. WhileFIG. 1A illustrates a single sheet of material or glass 112, embodimentsof the present disclosure should not be so limited as a multi-layerstructure 120 can also be mounted onto a suitable backing frame 114 asillustrated in FIG. 1B. Of course, exemplary backing frames can also besolid backing frames 117 as illustrated in FIG. 1C.

An exemplary, non-limiting backing frame or structure 114, 117 can beconstructed of a piece or multiple pieces of material having a modulusof elasticity>2 GPa and a thickness greater than 3 mm. Exemplary backermaterials include, but are not limited to, polyvinyl chloride (PVC),polycarbonate, phenolic materials (e.g., Trespa and the like), steel,wood, aluminum, glasses (e.g., soda lime glass and the like), ceramics,other metals, etc. These backer materials can be in the form of a frameas in FIGS. 1A and 1B and can be in the form of a substantially solidbacking device as in FIG. 1C. In alternative embodiments, the backingframe (as in FIGS. 1A and 1B) or the solid backing device (as in FIG.1C) can be in the form of a honeycomb or has a honeycomb structure.Exemplary materials for the honeycomb backer can be, but is not limitedto, aluminum, steel, ceramic, polymer, graphite, carbon, andcombinations thereof.

With continued reference to FIG. 1B, the multilayer structure 120 caninclude one thin glass sheet 121 and a second glass sheet 122 having apolymer interlayer 123 therebetween. Exemplary glass sheets 121, 122 canbe formed from any suitable chemically-strengthened glass, thermaltempered glass, heat strengthened glass, annealed glass, soda limeglass, and glass ceramics, just to name a few. In some embodiments, thefirst or external glass sheet 121 can be chemically strengthened glassand the second or interior glass sheet 122 can be non-chemicallystrengthened. Of course, embodiments of the present disclosure canemploy exemplary polymers or plastics in the place of the glass sheets.Exemplary polymeric materials include, but are not limited to, polyvinylbutryal (PVB), ethylene vinyl acetate (EVA), SentryGlass® or otherisomers, polycarbonate, acrylic, and the like. Exemplary embodimentsdepicted in FIGS. 1A-1C can include chemically strengthened glass sheetsor glass laminate structures bonded with one or more layers of ananti-splinter, adhesive film 116 to the backing frame 114 or fullbacking structure 117. Additional glasses, coatings, and/or glassceramics can be employed in embodiments of the present disclosure toprovide a variety of optical characteristics such as, but not limitedto, varying transparency characteristics (e.g., active devices such as,but not limited to, electrochromic and passive control such as photo orthermochromic control with heat and/or wavelength tuned control oftransparency), anti-glare characteristics, anti-reflectioncharacteristics, structural characteristics (embossments, inclusions,cold or hot formed structures), mirrored surfaces, electrical circuitry(printing or deposition of circuitry by screen printing, ink jetprinting, ITO, vapor deposition and the like) for transparent displaysand electroluminescent displays. In some embodiments, the film layer 116can include a plurality of decorative layers. Such decorative layers canbe painted, ink jetted, or otherwise deposited directly on the glasssheet or glass laminate structure, deposited on a vinyl layer (eithercast or calendered, with or without embossments in the adhesive layerfor pathways of air escape during lamination), deposited on PVB such asSentry Glass Expressions or other printable PVB, or deposited on othertypes of interlayers and films such as EVA, thermoplastic polyurethane(TPU), and polyethylene terephthalate (PET), to name a few, with orwithout embossments in the adhesive layer for pathways of air escapeduring lamination. Of course, the interlayer could also express the sameor similar optical attributes as stated above.

Applicant conducted ball drop on embodiments of the present disclosuredescribed above and conducted use case testing with metal hand trucksand pallet jacks impacting into exemplary modular glass panels of thepresent disclosure. Each of Applicant's embodiments surpassed numerousANSI test requirements (ANSI Impact, ANSI indoor aging, deflection, E84and 16 CFR Impact).

FIG. 2A is a top plan view of another embodiment of the presentdisclosure. FIG. 2B is a cross-sectional view of the embodiment of FIG.2A along line A-A. FIG. 2C is a detailed view of FIG. 2B. With referenceto FIGS. 2A-2C, an exemplary modular glass panel 200 can include one ormore glass sheets or glass laminate structures as described above. Whilethe modular glass panel 200 is illustrated in rectangular form, theclaims appended herewith should not be so limited as exemplary modularglass panels 200 can be any geometric form such as, but not limited to,circular, oval, square, hexagonal, trapezoidal, etc. Additionally, it isenvisioned that any glass panel shape, whether symmetrical orasymmetrical, can be cut and formed as appropriate and an exemplarybacking panel affixed thereto. The modular glass panel 200 in thisnon-limiting embodiment can provide a backing frame 210 extending alongthe perimeter 212 of the glass panel. In some embodiments, backing frame210 can fully frame or enclose the edges of the glass sheet 112 orlaminate structure or, in other embodiments, can leave the edges thereofexposed whereby the edges of the glass sheet 112 or laminate structureoverhang the backing frame 210 or are set back or flush with the edge ofthe backing frame 210. In a preferred embodiment, the glass sheet 112 orlaminate structure is substantially flush or set back from the backingframe 210 edge.

In additional embodiments of the present disclosure, the glass sheet 112or laminate structure can be rendered to a safety glass. For example,exemplary glass sheets can be made as a safety glass by employing asuitable bonding polymer (e.g., a variety of 3M Safety Films are madefor this purpose) on the rear or back side of the glass sheet. It alsofollows that laminated glass structures, e.g., glass-to-glass sheets orglass sheet to polymeric material to glass sheet are also examples ofsafety glasses. Exemplary, non-limiting constructions of glass panelingor laminate structure paneling include a glass/interlayer/glassconstruction with the interlayer comprising PVB, EVA, Sentry Glass, PET,or another energy absorbing or dispersing polymer. Such an embodimenthas been experimentally tested and surpassed ANSI test requirements forresistance against impact and for retaining broken glass pieces when therespective panel was finally fractured. Such exemplary constructions canalso accommodate any decorative and/or lighting qualities of the panelon a solid or framed backing device. In some exemplary embodimentshaving a backing frame, the space or area 220 defined or encompassed bythe perimeter frame 210 permits the use of the glass or laminate panelas a speaker, receiver, microphone, and the like, whereby the acousticactuators can be adhered to the interior of the glass panel and therespective acoustic components, e.g., amplifiers, transducers, and thelike, contained within the encompassed area 220. Additionally, the glassor laminate panel can be utilized as a cover glass for touch screendevices mounted directly to the glass or glass laminate panel andsubstantially contained in the encompassed area 220. In furtherembodiments of the present disclosure, lighting devices and componentssuch as, but not limited to, light emitting diodes (LEDs), arrays ofLEDs, and other luminaires can be substantially contained in theencompassed area 220 whereby the light given therefrom is emittedthrough the glass or glass laminate panel. For example, in oneembodiment, separate LED panels can be placed behind a glass panel(which may not be transparent but employs diffuse mechanisms (e.g.,anti-glare coating on one or both sides of the panel, etched (dipped,sprayed, deposited)) or other structured light qualities incorporating avariety known decorative designs). In another embodiment, LED strips orindividual LEDs can be positioned around the perimeter of an exemplarypanel to use the glass or laminate structure as a waveguide, dispersinglight such that the glass panel glows. Thus, in such embodiments,portions or all of the glass or glass laminate panel can includediffusing mechanisms including coatings or the like to diffuse orotherwise alter incident light on one side of the glass or glasslaminate panel thereby providing an altered or diffused refracted light.

In some of these embodiments, the intensity of emitted light can becontrolled by several mechanisms such as, but not limited to, dimmers,manual variable controls, voice, motion or heat activated controls (orother automated, computer controlled, manually controlled mechanisms) toreduce heat produced by radiant energy. To reduce or eliminate lighting“hot spots” (areas where people perceive the light source) and create auniform lighting, the glass or laminate material can be etched to createa diffuse surface. For example, opal glass can be employed to produceuniform lighting for microscopy or photography or holography. Othermeans of creating uniform lighting through the use of holographicdiffusers, chemical etchants, sand or bead blasting glass can also beemployed in embodiments of the present disclosure. Diffusers can also beengineered to deliver or convert almost any type of diffusion profilefrom non-uniform output light sources such as LEDs. One exemplarynon-limiting engineered diffuser includes a variable diffusermanufactured by Luminit, LLC. Exemplary diffusion profiles can rangefrom narrow line to a broad Lambertian profile to homogenize non-uniformlight emitted from many sources, including LEDs. Holographic, etched,and opal glass diffusers are generally available from such sources asEdmund Optics. Engineered diffusers are obtainable from RPC, Inc. In oneembodiment, a diffusing panel can be placed between an LED panelcontained in an encompassed area 220 and one of the glass panels affixedthereto by optically clear adhesives. In another embodiment, a diffuserelement can be a part of the glass used in the panel. Diffusers soemployed can thus be designed to modify lighting conditions across anexemplary panel to create unique patterns for decorative and/orfunctional lighting displays. Thus, in some embodiments the glass orglass laminate panel can also include a variety of materials selectedfor their unique properties in creating a light-weight, strong, visuallyappealing and user interactive panel.

In further embodiments, the front surface of the glass or glass laminatepanel can provide a variety of attributes for aesthetics, safety, anduser interaction. For example, the glass surface can include anti-glare,anti-reflection, anti-fingerprint, anti-viral, anti-bacterial or othercoatings produced by mechanical or chemical means.

With continued reference to FIGS. 2B and 2C, an exemplary backing frame210 can include a substantially rectangular or square cross sectionwherein an interior edge 211 thereof is rounded in form. This roundededge 211 can accommodate any flexure, deflection or bending 217 of theglass or glass laminate panel and does not provide a sharp edge as wouldotherwise be present with a fully rectangular or square cross section.FIGS. 3A and 3B are detailed views, similar to FIG. 2C, of furtherembodiments of the present disclosure whereby the backing frame includesa circular 213 or domed 215 cross section. Again, in each of theseembodiments, an interior edge 221 and in some cases exterior edge 223presents a rounded form to prevent a sharp edge from contacting theadjacent glass panel or glass laminate structure. Of course, while thecross sectional geometries have been illustrated as rectangular orsquare (FIGS. 2B, 2C) with a rounded edge, or circular (FIG. 3A), ordomed (FIG. 3B), the claims appended herewith should not be so limitedas the cross section can be any number of geometries, e.g., oval,hexagonal, trapezoidal, asymmetrical, etc., so long as the edges of suchgeometric form are rounded on the interior edge of the backing frame. Ofcourse, while the embodiments of the present disclosure have beenillustrated as having a single glass sheet 112 adhered to a backingframe with an adhesive layer 116, the claims appended herewith shouldnot be so limited as exemplary embodiments can include multilayer glasslaminate structures described herein and illustrated in FIG. 1B. Inembodiments of the present disclosure where the glass panel is not flushto the backing frame, both edges, the interior edge and exterior edgewould present a rounded edge to the adjacent glass panel or laminatestructure to prevent a sharp profile thereto. Additionally, while thecross-sectional illustrations are shown as solid core frame embodiments,it is envisioned that the frames can be hollow in nature thereby furtherreducing the weight of an exemplary modular panel. Thus, the claimsappended herewith should not be so limited to a solid frame core. Asnoted above, embodiments of the present disclosure can employ a fullbacking device or a hollow- or solid-core backing frame with single orplural glass sheets of about 0.5 mm to 2 mm thickness. Such backingdevices or frames can thus allow panelization of the glass or laminateboard without the need for point supported hardware; however,embodiments of the present disclosure can also be point supported usinga variety of common hardware options such as spider clamps and the like(preferably non-penetrating, but through-holes are also envisioned).

FIG. 4 is an illustration of some embodiments of the present disclosure.With reference to FIG. 4, a series of planar surfaces 400 is presentedhaving embodiments of the present disclosure mounted thereon. In someembodiments, these planar surfaces 400 can form one or more walls and/ora ceiling in an elevator cab. In other embodiments, these planarsurfaces 400 can form walls or other surfaces in a lobby, room or otherinterior or exterior environment. More specifically, FIG. 4 provides anexemplary system of panels incorporating high resolution mural graphics,diffuse lighting panels (ceiling or wall), solid colors, wood and steelvignettes, touch screen information devices, and panels that can operateas speakers or microphones and/or include wireless or wired control oflighting, sound systems, interactive videos, and data transfer (e.g.,Bluetooth) to hand held devices. For example, the Corning ONE Wirelessplatform can be utilized with embodiments of the present disclosure andcan be integrated in the cavity or encompassed area 220 of someembodiments or can be situated in other portions of exemplaryembodiments. Of course, other distributed wireless or antenna systemscan be employed to gather and/or disseminate information to deviceswithin a space or exterior to a space such as handheld devices,smartphones and the like for purposes of freely sharing information(information way points) or as points of sale (POS). Additionally,wireless sensor networks (WSN) for environmental monitoring feedback andcontrol, can also be employed with embodiments of the presentdisclosure. It should be noted that the depiction of the planar surfaces400 in a confined area should not limit the scope of the claims appendedherewith. As depicted in FIG. 4, modular glass panels according toembodiments of the present disclosure can be employed along vertical,horizontal or other planar surfaces of a structure. One embodiment asheretofore described can be employed in the ceilings 410 of an interioror exterior structure such as, but not limited to, an elevator cab, as alight illuminating structure having LEDs, arrays of LEDs, light emittingfibers, lasers, or other luminaires or light emitting devices containedin an encompassed area defined by an exemplary backing frame. Otherembodiments can be employed in ceilings or side panels 420 with displaysor active displays contained in an encompassed area defined by anexemplary backing frame. Such an embodiment 420 can fully utilize thetouch concept advantages of thin glass as heretofore described. Thus,exemplary embodiments can also include displays (passive and/or active)and interactive transparent displays. Interactivity can be achievablethrough touch, voice, and/or personal mobile (electronic or photonic)devices. Exemplary non-limiting materials for cover glass can alsoinclude electrochromic and photochromic glass (e.g., dynamic or smartglass) for transparency and reflectance control. Additional embodimentscan be employed in side panels 430 having decorative features (e.g.,pictures 431, marbling 432, solid colors 433, wood 434, and the like).Of course, in these embodiments, the decoration can be ink jetted orotherwise deposited on an interior face of the respective panel or canbe a portion of or all of the respective backing frame. It should benoted that the thinness and high transparency of embodiments of thepresent disclosure permit an image that is printed on the back surfaceto be seen as being directly on the surface of the front face of theglass. Apparent depth of decorative layers can thus be controlled byadding layers to the thickness of the decorative stack. Layers added bysingle or multiple lamination steps of two or more pieces of glass,plastic, interlayers, and decorative element are envisioned inembodiments of the present disclosure.

Exemplary backing frames according to embodiments of the presentdisclosure can employ and accommodate any means of fixation to walls,elevator cabs, or other architectural structures including, but notlimited to, removable and reconfigurable partitions for office spaces,lobbies, hallways, entryways, etc. Some of the non-limiting examples ofsuch fixation mechanisms are tongue in groove type designs, clipdesigns, point bonding to glass such as the Guardian® spider fixtures,corner frame mortices, tapes, films and other adhesives (such as VHBseries or the OCA series from 3M, TESA, Dow-Corning adhesives, Sikaadhesives, or removable adhesives such as 3M quick release products) fordirect bonding of the glass or glass laminate panel to existing walls orframes. Such connection and fixation mechanisms can also be employed toattach periphery and enabling technologies to exemplary embodiments of aglass or glass laminate panel.

Embodiments of the present disclosure are generally modular in designthus allowing for ease of replacement of panels should a panel fractureor be replaced due to aesthetic purposes. For example, changing anexemplary panel of solid color to one that is a touch display of thesame dimensions can minimize rework/refitting on site due to theconstruction of such embodiments, thus panel installation can beagnostic towards panel functionality. For embodiments requiring addedstiffness, an exemplary panel construction can be made of multiple thinglass layers or a hybrid construction of thin chemically strengthenedglass and thicker soda lime glass (annealed, heat strengthened,thermally tempered). Such a laminate construction can retain thestrength, hardness and optical clarity of thin, chemically-strengthenedglass (e.g., Gorilla® Glass) while still maintaining a lighter weightadvantage over all conventional soda lime glass constructions.

While not shown, some embodiments of the present disclosure can includeadditional impact absorbing mechanisms such as, but not limited to,grommets and absorption pads (e.g., rubbers, silicones, elasticpolymers, viscoelastic materials, and the like). These absorptionmechanisms or pads can be positioned at supports and other impactabsorbing points of contact improve the break resistance of the panelsystem. Sorbothane, polynorbornene, noene, astro-sorb, memory foam, andneoprene are some but not all examples of viscoelastic materials. Shearthickening materials in which viscosity increases with the rate of shearstrain may also be used at strategic points to stiffen the structureduring impact events.

One exemplary embodiment of the present disclosure provides a modularglass panel having a glass structure having at least one thin glasssheet with a thickness ranging from about 0.5 mm to about 2.0 mm, abacking frame positioned adjacent the glass structure and situated alongthe perimeter of the glass structure, and a polymer layer intermediatethe glass structure and backing frame to adhere the glass structuretogether with the backing frame. In some embodiments, the thickness ofthe at least one thin glass sheet ranges from about 0.5 to 1.5 mm, from0.5 mm to about 1.0 mm or from about 0.5 mm to about 0.7 mm. In otherembodiments, the glass structure further comprises the at least one thinglass sheet and a second glass sheet having a polymer interlayertherebetween. This thin glass sheet can be a thin,chemically-strengthened glass sheet. In other embodiments, the secondglass sheet can be, but is not limited to, a chemically-strengthenedglass sheet, a thin chemically-strengthened glass sheet, a soda limeglass sheet, and a monolithic tempered glass sheet. Either the secondglass sheet or the at least one thin glass sheet can be adjacent thebacking frame. Exemplary polymer interlayers can be, but are not limitedto, PVB, EVA, TPU, PET, and combinations thereof. In additionalembodiments, exemplary backing frames can possess a cross-section suchas, but not limited to, a substantially rectangular cross-section with arounded interior edge adjacent the glass structure, a substantiallysquare cross-section with a rounded interior edge adjacent the glassstructure, a circular cross-section, a domed cross section, asubstantially rectangular cross-section with rounded interior andexterior edges adjacent the glass structure, a substantially squarecross-section with rounded interior and exterior edges adjacent theglass structure, asymmetrical cross-sections, and symmetricalcross-sections. It is also envisioned that exemplary modular glasspanels further comprise a plurality of decorative film layers and canalso include one or more coatings of material such as, but not limitedto, an anti-glare material, anti-reflection material, anti-fingerprintmaterial, anti-viral material, anti-bacterial material, anti-splintermaterial, and combinations thereof, provided on one or both planarsurfaces of the glass structure. In some embodiments, the backing framecan define a space containing a device selected from the groupconsisting of a light source, a LED, an array of LEDs, a laser, a lightemitting fiber, a luminaire, a speaker, a microphone, a display,electronic devices, and combinations thereof. Such exemplary modularglass panels can be installed as a planar surface in an interiorenvironment selected from the group consisting of a wall, an elevatorcab, a lobby, a ceiling, a hallway, an entryway, and a room. Inadditional embodiments, the backing frame can be comprised of a materialsuch as, but not limited to, polyvinyl chloride, polycarbonate, glasses,phenolic material, steel, wood, aluminum, ceramics and combinationsthereof.

Another exemplary embodiment of the present disclosure provides amodular panel comprising a planar structure, a backing frame positionedadjacent the planar structure and situated along the perimeter of theplanar structure, the backing frame have a geometric cross-section witha rounded interior edge adjacent the planar structure to preventbreakage of the planar structure upon loading or impact of an exteriorsurface of the planar structure, and a polymer layer intermediate theplanar structure and backing frame to adhere the planar structuretogether with the backing frame. Exemplary planar structures can be, butare not limited to, a thin glass sheet, a polymeric material, and amulti-layer laminate structure, and combinations thereof. Exemplary thinglass sheets can have a thickness ranging from about 0.5 to 2.0 mm, fromabout 0.5 to 1.5 mm, from about 0.5 mm to about 1.0 mm or from about 0.5mm to about 0.7 mm. If the embodiment employs a multi-layer laminatestructure, this structure can include at least one thin glass sheet anda second glass sheet having a polymer interlayer therebetween. In anyembodiment, the thin glass sheet can be a thin, chemically-strengthenedglass sheet. In some embodiments, the second glass sheet can be, but isnot limited to, a chemically-strengthened glass sheet, a thinchemically-strengthened glass sheet, a soda lime glass sheet, and amonolithic tempered glass sheet. In multilayer embodiments, the polymerinterlayer can be but is not limited to, PVB, EVA, TPU, PET, andcombinations thereof. Exemplary geometric cross-sections can be, but arenot limited to a substantially rectangular cross-section with a roundedinterior edge adjacent the glass structure, a substantially squarecross-section with a rounded interior edge adjacent the glass structure,a circular cross-section, a domed cross section, a substantiallyrectangular cross-section with rounded interior and exterior edgesadjacent the glass structure, a substantially square cross-section withrounded interior and exterior edges adjacent the glass structure,asymmetrical cross-sections, symmetrical cross-sections. It is alsoenvisioned that exemplary modular panels further comprise a plurality ofdecorative film layers and can also include one or more coatings ofmaterial such as, but not limited to, an anti-glare material,anti-reflection material, anti-fingerprint material, anti-viralmaterial, anti-bacterial material, anti-splinter material, andcombinations thereof, provided on one or both planar surfaces of theplanar structure. In some embodiments, the backing frame can define aspace containing a device selected from the group consisting of a lightsource, a LED, a light emitting fiber, a laser, an array of LEDs, aluminaire, a speaker, a microphone, a display, electronic devices, andcombinations thereof. Such exemplary modular panels can be installed asa planar surface in an interior environment selected from the groupconsisting of a wall, an elevator cab, a lobby, a ceiling, a hallway, anentryway, and a room. In additional embodiments, the backing frame canbe comprised of a material such as, but not limited to, polyvinylchloride, polycarbonate, phenolic materials, glasses, steel, wood,aluminum, ceramics and combinations thereof.

It is thus an aspect of embodiments of the present disclosure to providereconfigurable panels having lighter weight (installation, handling,shipping, processing during decoration), greater optical transmission inthe optical range (maintain color purity of decorations), greaterflexibility for decorative designs, enabled touch functionality,speakers or speaker/microphone combinations, scratch resistance andimpact resistance in comparison to conventional solutions.

While this description can include many specifics, these should not beconstrued as limitations on the scope thereof, but rather asdescriptions of features that can be specific to particular embodiments.Certain features that have been heretofore described in the context ofseparate embodiments can also be implemented in combination in a singleembodiment. Conversely, various features that are described in thecontext of a single embodiment can also be implemented in multipleembodiments separately or in any suitable subcombination. Moreover,although features can be described above as acting in certaincombinations and can even be initially claimed as such, one or morefeatures from a claimed combination can in some cases be excised fromthe combination, and the claimed combination can be directed to asubcombination or variation of a subcombination.

Similarly, while operations are depicted in the drawings or figures in aparticular order, this should not be understood as requiring that suchoperations be performed in the particular order shown or in sequentialorder, or that all illustrated operations be performed, to achievedesirable results. In certain circumstances, multitasking and parallelprocessing can be advantageous.

As shown by the various configurations and embodiments illustrated inFIGS. 1-4, various embodiments for modular wall panels and planarstructures have been described.

While preferred embodiments of the present disclosure have beendescribed, it is to be understood that the embodiments described areillustrative only and that the scope of the invention is to be definedsolely by the appended claims when accorded a full range of equivalence,many variations and modifications naturally occurring to those of skillin the art from a perusal hereof.

What is claimed is:
 1. A modular glass panel comprising: a glassstructure having at least one glass sheet with a thickness ranging fromabout 0.5 mm to about 2.0 mm and a perimeter; a backing frame positionedadjacent the glass structure and situated along the perimeter of theglass structure; and a polymer layer intermediate the glass structureand backing frame to adhere the glass structure together with thebacking frame, wherein the backing frame defines a space containing adevice selected from the group consisting of a light source, a lightemitting diode (LED), an array of LEDs, a luminaire, a speaker, amicrophone, a light emitting fiber, a laser, a display, electronicdevices, and combinations thereof.
 2. The modular glass panel of claim 1wherein the thickness of the at least one glass sheet ranges from about0.5 mm to about 1.5 mm.
 3. The modular glass panel of claim 1 whereinthe glass structure further comprises the at least one glass sheet and asecond glass sheet having a polymer interlayer therebetween.
 4. Themodular glass panel of claim 3 wherein the at least one glass sheet is achemically-strengthened glass sheet.
 5. The modular glass panel of claim4 wherein the second glass sheet is selected from the group consistingof a chemically-strengthened glass sheet, a soda lime glass sheet, and amonolithic tempered glass sheet.
 6. The modular glass panel of claim 5wherein the at least one glass sheet is adjacent the backing frame. 7.The modular glass panel of claim 3 wherein the polymer interlayer isselected from the group consisting of polyvinyl butyral (PVB), ethylenevinyl acetate (EVA), thermoplastic polyurethane (TPU), polyethyleneterephthalate (PET), and combinations thereof.
 8. The modular glasspanel of claim 1 wherein the backing frame has a cross-section selectedfrom the group consisting of a substantially rectangular cross-sectionwith a rounded interior edge adjacent the glass structure, asubstantially square cross-section with a rounded interior edge adjacentthe glass structure, a circular cross-section, a domed cross section, asubstantially rectangular cross-section with rounded interior andexterior edges adjacent the glass structure, a substantially squarecross-section with rounded interior and exterior edges adjacent theglass structure, asymmetrical cross-sections, symmetricalcross-sections.
 9. The modular glass panel of claim 1 wherein thebacking frame is comprised of a material selected from the groupconsisting of polyvinyl chloride, polycarbonate, phenolic material,steel, glass, wood, aluminum, ceramic and combinations thereof.
 10. Themodular glass panel of claim 1 wherein the backing frame includes ahoneycomb structure comprising a material selected from the groupconsisting of aluminum, steel, ceramic, polymer, graphite, carbon, andcombinations thereof.
 11. The modular glass panel of claim 1, whereinthe thickness of the at least one glass sheet ranges from about 0.5 mmto about 0.7 mm.
 12. The modular glass panel of claim 1, wherein thebacking frame comprises a fixation mechanism so that the modular panelcan be removably attached to a planar surface selected from the groupconsisting of a wall, an elevator cab, a ceiling, a hallway, anentryway, and a room.
 13. The modular glass panel of claim 12, whereinthe fixation mechanism is selected from the group consisting of a tonguein groove type design, a clip design, point bonding, corner framemortices, films and adhesives.
 14. An architectural structurecomprising: the modular glass panel of claim 12, wherein the backingframe is removably attached to the planar surface by the fixationmechanism.